Contrary to what many think, just because we finally got to take this build to the Pa. All Breed Jeep Show it is not totally done. (Are they ever?) We had a few things that needed completion and with winter storage and presents under the Xmas tree it was an opportunity to take care of them. One item missing was sunvisors. A cruise thru Amazon netted us a pair from Rugged Ridge in black. Easy wrap job and thru them under the tree. Installation was straight forward. The windshield frame was already tapped for 10-32 screws. Pulled 8 stainless button head cap screws out of inventory and done. The rear view mirror that we had installed was a glass mount verses the windshield

frame mount and is pretty wide and interferes with the visors in the down position. Gonna have to look for a smaller mirror. There is a birthday coming up in April so that will be another gift. Next item was the soft top channels along the top of the half doors. They were already painted black from original and had alot of wear and scratches and looked awful against the newly painted doors. Removed them and sent them off to the Powdercoaters and had them done in black. A strip of foam was adhered to the mounting surface to protect the door paint and reinstalled. Made a huge difference in appearance. Other items that we had previously taken care of was a larger radiator overflow tank, it was being sucked dry causing some cooling issues and a 

blocked overflow hose allowing the upper radiator hose to collapse. We'll keep you posted on updates.

 Manbeck Alignment was next on the list to do. An appointment was made and it was determined that one of the neutral cam adjusting bushings that we installed was threaded in too deep and also they did not have the required offset bushings in stock to properly do the alignment. So we rescheduled until the correct bushings were acquired. Getting the old bushings out was a bit of a chore but they were successful. Turns out the alignment was not that far off, so there were no noticeable driving conditions. Next stop was over our home grease pit for an oil and filter change using Brad Penn oil. This oil has a higher operating temperature along with higher zinc levels. A final inspection was made to make sure everything was tight and checking all fluids, belts and hoses. Finally off to Ryan Boyer

Detailing in near by Pine Grove. This guy runs his own detailing shop and also works for Mecum Auctions doing final detailing on cars before they go across the auction block. He uses all the new technology and the results are stunning, Needless to say he made the black look like it was just painted. July 23rd came quick with the promise of clear weather, although mid 90's hot. This was going to be a test of the CJ's capabilities. Our gear was packed and we

departed around 7:00 AM. 1st stop was to top off the gas tank with 93 octane. We stuck to secondary roads until we got to Linglestown exit at I-81 and a friend tagged along with his XJ. Took I-81 across the river then secondary roads again into Carlisle. Traffic was horrendous getting to the fairgrounds. We sat 45min. in traffic keeping our eyes on the temp gauge which hung around 195 which indicated the electric fans were doing their job. Finally

entered the fairgrounds and with the outside temperature at high 90's the temp gauge started climbing above 225. The air being pulled in was just extremely hot. We decided to pull out of line and shut it down. Opened the hood and nothing was boiling over. We eventually made it to our class sight and set up the canopy and chairs and broke out a cold one. The show was great, met alot of great people and terrific Jeeps. We were in class 3 (all CJ's

and Commandos) that also had 3 categories (stock),(modified) and (unlimited modified). We were in the unlimited. All total there was 1 stock Jeep, 3 modified and 8 unlimited. Sitting on the bleachers listening at the judging results was tense. The announcer called 3rd. place, 2nd. place and finally Jeffs name for 1st. place. The dream of a 14yr old kid to build a Jeep and take 1st. at PA. All Breeds Jeep show

became a reality. We have alot of people to thank for making this all possible and an 18yr venture that will hold uncountable memories.

 

Stripe kit arrived from Phoenix Graphix. The 1980 to 1984 version was chosen. Packed it all in the CJ and dropped it off at Garys for application. Also while there, two areas of body work had to be addressed. When we originally installed threaded anchors along the beltline for top installation a hardtop was used for locations. The soft top rails use additional anchor points so a separate anchor was installed next to the hardtop location. When installing the soft top rail that area cracked out. It was remedied by cutting both anchors out and replacing with a single one with two threaded holes, one for soft top and one for hardtop. The other location that gave a problem was the drivers

side front door opening where the door stap is located. In full open position the area of the opening that was contacted by the strap crushed that spot due to a void in the fiberglass. That was also cut open and filled with resin to make it solid. Both areas had to then be repainted and as usual Garys did not disappoint. The paint blending can't be seen. Once the body work was done it was handed over to Rick (who owns Garys) to apply the stripe kit. Application went well. Two areas that didn't suite Ricks perfection, and no fault of his was a slight angular mismatch where the rocker stripe meets the rear wheel opening stripe. This was on Phoenixs shoulders, but in all reality would

normally be overlooked. The other area was where the front fenders are fastened to the grille. The fenders at this point should curve down to utilize all mounting bolts. One fender when received from Shell Valley was over trimmed at the bottom and cut straight missing the lower bolt completely. Not knowing how this would affect the stripe kit in the future the opposite fender we trimmed to match. In retrospect the fender should have been returned for a replacement. The stripe kit follows this curvature, therefor it had to be cut and respliced to work. Rick did a fine job in doing so. Again would be overlook unless you knew. The stripe kit also comes with a beltline stripe that extends onto the

full doors if utilized. Since we are using YJ half doors this full door body line does not exist, therefore was not used. We later decided to use that stripe on the body tub wrapping it around the rear corner, and then cutting the straight section off the door stripe and applied it to the tailgate. The rear was a bit plain not having a spare tire mounted, so this stripe accents that area. Next on the to do list is a front end alignment. This will be handled by Manbeck's Alignment in nearby Schuylkill Haven, followed by detailing and paint protection by Boyer's Auto Detailing on Pine Grove.

                                                                                                                                                                                                                                                        Back from Powdercoat and as usual a fine job. I wasn't too worried about my lousy welds on the steps since they would be coated with Line - X Before delivering to Gary's for an application of black, steel plates were cut out in the shape of the Jeep grille and bolted to the steps covering the slots and holes. These acted as a mask which would be removed after coating exposing the powdercoated slots. At Gary's I was allowed to witness the process of application. All I can say, it is an art, and can now appreciate the time and effort that goes into this process. It's not as simple as you think. The Line-X dries almost immediately, allowing cutting with a utility knife around the steel plate

masks, and removing, exposing the grille slots. The look is what I was hoping for. It's subtle, but there if your observant. Assemble of the main structure was straight forward, since everything was prefitted in advance. 5/16" stainless bolts with stainless lock nuts (12 per side) were used along with leveling washers from McMaster Carr These were needed due to the fact that structural channel was used for the frame extensions, which have tapered legs. Without using these washers there would be no flat surface for the nut to seat against, causing stress on the bolts possibly weakening them. The steps were then mounted using 1/2" stainless button head hex drive bolts along with stainless lock washers. Next on the to do list is the application of the Laredo

stripe kit, in which Gary's will also be applying. 

Now that we have the location for the step the next critical dimension was the height. Making it too high could be a problem for head clearance making it necessary to duck while entering. Too low making it necessary to climb in. Also ground clearance could be an issue (not that we will be rock crawling with it) but a consideration never the less. Experimenting with different block heights a compromise was met taking in functionality and looks. Cardboard patterns were made up then transferred to steel plate. Cut out on the band saw, drilled and then bent. 1" steel shafting was cut to length and the ends drilled and tapped for 1/2 - 13 thread. A sheet metal plate was then cut to bridge

the gap between the shafts and tack welded. The assembly was then tack welded on to the 3 x 2 side rails. Bolted back on to the Jeep verified that everything was copacetic. Final welding was performed after removal. The steps were made to be unbolted from the main structure because they will be covered with Line-X for a slip free surface after Powdercoating. Since they were removable it was decided to dress them up a bit by milling the Jeep grille logo into them. After some final grinding they were delivered for powdercoating, then off to get Line-X.

Just as we got this all legal, it was time to put it away for the winter. I had a few things to finish up on my own project, (a 1967 Olds 442) like to finish up the power window conversion and front coil springs. Now that those things were done our attention was focused on the running board steps for the Jeep. Looking what was available thru the after market wasn't going to work since most are fastened to the body. Our fiberglass body I knew would eventually be a problem. The solution was to fasten it directly to the frame. There were 3 frame extensions off the main frame rail on each side that could be utilized. The 2 rear ones were further towards the back than what the step would be, and

only using those would not be very supportive. All 3 had to be tied together. Since the wheel opening flares stuck out past the body it was decided to incorporate them into the running boards for a continuous visual flow. I guess on a performance car it would be called ground effects. Not that this build would benefit from ground effects, but you get the picture. 3" x 2" x 1/8" wall rectangular steel tubing 5' long for each side was purchased from Steel Metal Service Center in Pottsville, Pa. along with some 1/4" x 1-1/2" flat bar. Mocking it up with a pair of jack stands, measurements were taken for the flat bar. These were cut to length and pre drilled then clamped to the frame extensions.

Using the pre drilled holes as a guide the frame extensions were drilled, then bolted in place with 5/16" bolts. The tubing was then butted up against them and tack welded, then removed and finish welded. Reinstalled, then the curvature of the flares were layed out on the tubing ends. These were then cut and end caps were fabricated from sheet metal and welded on, the rear one extending up to meet the flare. Locations for the steps were located by entering and exiting the Jeep and marking where your foot was the most comfortable. Next post we will fab up the steps.